DMREF/GOALI: Novel 3D Experiments, Simulations, and Optimization for Accelerated Design of Metallic Foams

开孔金属泡沫是一类令人兴奋的结构材料，其包括互连金属韧带的网络，从而产生有趣的泡沫结构。这些低密度材料在过去的二十年里因其在多功能应用中的公认潜力而备受关注。例如，除了作为轻质承重结构外，开孔金属泡沫还可以同时作为储能装置的电极，作为生物医学植入物中新生成的骨骼和血管的宿主，或者作为先进高速地面运输的冲击吸收器和隔音器。尽管具有潜力，但开孔金属泡沫在更广泛的多功能应用中的广泛部署仍然受到低效的试错制造方法的阻碍。这个设计材料革命和工程我们的未来（DMREF）授予机会学术联络与工业（GOALI）奖支持学术界和工业界的联合研究工作，以实现更有效和智能的开孔金属泡沫设计，并实现对目标应用性能的精确控制。研究结果将通过提高泡沫的制造效率和可定制性为该行业提供显着的改进，这将有助于在整个能源，国防，生物医学，航空航天和汽车行业中扩大泡沫的部署。该研究团队将举办外展活动，让K-12学生、本科生和研究生接触到这项多学科的STEM研究。DMREF GOALI奖支持研究，通过将3D材料表征中的紧急方法与多尺度建模和贝叶斯优化相结合，为开孔金属泡沫提供加速和基于性能的设计范例。新的设计范式将通过发现泡沫中的工艺-结构-性能关系而成为可能。具体目标包括：实验性地修改制造参数以生产开孔金属泡沫的变体;进行基于3D同步加速器的晶体取向测量和原位X射线计算机断层扫描实验以获得对泡沫的分级结构和多尺度变形机制的前所未有的洞察;使用高保真度，多尺度（颗粒到连续体）有限元建模，以研究所制造的泡沫的微观力学行为和预测性能;对合成泡沫变体进行虚拟测试以进一步填充金属泡沫设计空间;以及对基于模拟的结果使用贝叶斯优化以使得能够选择用于目标性能度量的最佳分层结构（即拓扑和晶体学）。这项研究将是第一次解耦韧带拓扑结构和底层晶体结构对开孔金属泡沫微观力学行为（包括微屈曲，滑移的局部积累和裂纹成核位点的分布）的影响，这被认为会影响其性能。

Open-cell metallic foams are an exciting class of structural materials that comprise a network of interconnected metallic ligaments, resulting in an interesting foam architecture. These low-density materials have garnered much attention over the past two decades based on their recognized potential for use in multi-functional applications. For example, in addition to serving as light-weight, load-bearing structures, open-cell metallic foams have the potential to serve concurrently as electrodes for energy-storage devices, as hosts for newly generated bone and blood vessels in biomedical implants, or as impact absorbers and noise insulators for advanced high-speed ground transportation. Despite their potential, the widespread deployment of open-cell metallic foams for a broader range of multi-functional applications remains hampered by inefficient, trial-and-error manufacturing approaches. This Designing Materials to Revolutionize and Engineer our Future (DMREF) Grant Opportunities for Academic Liaison with Industry (GOALI) award supports a joint academic-industry research effort to enable more efficient and intelligent design of open-cell metallic foams, and to achieve precise control over their performance for targeted applications. The results will provide dramatic improvements for the industry by increasing both the manufacturing efficiency and the tailorability of the foams, which will help to expand deployment of the foams throughout the energy, defense, biomedical, aerospace, and automotive industries. The research team will host outreach activities to expose students in K-12, undergraduate, and graduate school to this multi-disciplinary STEM research.This DMREF GOALI award supports research to enable an accelerated and performance-based design paradigm for open-cell metallic foams through the integration of emergent methods in 3D materials characterization with multi-scale modeling and Bayesian optimization. The new design paradigm will be made possible through the discovery of process-structure-property relationships in the foams. The specific objectives include: experimentally modifying manufacturing parameters to produce variants of open-cell metallic foams; performing 3D synchrotron-based crystal-orientation measurements and in-situ X-ray computed tomography experiments to gain unprecedented insight into the hierarchical structure and multi-scale deformation mechanisms of the foam; using high-fidelity, multi-scale (grain-to-continuum) finite-element modeling to investigate micromechanical behavior and predict performance of the as-manufactured foams; conducting virtual tests on synthetic-foam variants to further populate a metallic-foam design space; and using Bayesian optimization on the simulation-based results to enable selection of optimal hierarchical structures (i.e. topology and crystallography) for targeted performance metrics. The research will be a first to decouple the effects of ligament topology and underlying crystal structure on micromechanical behavior of open-cell metallic foams (including microbuckling, local accumulation of slip, and distribution of crack-nucleation sites), which is postulated to influence its performance.